Non-woven bags are manufactured through an integrated two-stage industrial chain: raw polypropylene (PP) polymer granules are first thermally extruded and filament-spun into spunbond fabric mother rolls, which are subsequently fed into fully automatic converting lines. Within high-speed converting machinery, the continuous fabric web undergoes optical web guiding, multi-station ultrasonic pattern sealing (15–20 kHz), inline loop handle welding, gusset tucking, and rotary knife cross-cutting, producing fully finished 3D carrier bags at up to 100 units per minute with zero manual needle stitching.
Video: Engineering walk-through of the fully automatic non-woven bag manufacturing and converting cycle.
When asking which material is used in non-woven bags, the overwhelming industrial standard is 100% Polypropylene (PP) homopolymer granules (melt flow index typically MFI 25–40 g/10min). Polypropylene is selected for its hydrophobic nature, high tensile-to-weight ratio, chemical inertness, and precise thermal plasticity—allowing the polymer to soften at ~130°C and melt completely at ~165°C for ultrasonic fusion.
In premium retail and circular economy sectors, modern packaging converting plants also utilize two high-performance sustainable alternatives:
Non-woven fabrics are categorized by web formation and mechanical bonding principles. In the manufacturing sector, the three primary types include Spunbond, Meltblown, and Spunlace:
| Non-Woven Type | Manufacturing Mechanism | Physical Characteristics | Primary Industry Application |
|---|---|---|---|
| 1. Spunbond Non-Woven | Continuous filaments extruded through spinnerets, aerodynamically drafted, and thermally bonded via calender rollers. | High tensile and tear strength, directional dimensional stability, cost-effective, GSM range 15–150 g/m². | Shopping bags, 3D box bags, agricultural covers, medical disposable gowns. |
| 2. Meltblown Non-Woven | High-velocity hot air attenuates molten polymer into ultra-fine microfibers (1–5 μm diameter). | Extremely high surface area, micro-porous filtration barrier, low mechanical tensile strength. | Air/liquid filtration, surgical face mask middle filter layer (BFE/PFE ≥ 99%), oil absorbent pads. |
| 3. Spunlace (Hydroentangled) | High-pressure water micro-jets entangle loose carded fibrous webs without thermal binders. | Exceptional cloth-like softness, high moisture absorbency, breathable, premium touch. | Cosmetic facial masks, wet wipes, surgical drapes, synthetic leather base substrates. |
For packaging converter operations, Spunbond non-woven is the exclusive substrate used for bag body and handle manufacturing due to its structural resistance against dynamic load forces (up to 20 kg).
Industrial conversion transforms non-woven fabric rolls into finished consumer carrier bags through an automated, multi-axis servo synchronization sequence. Below is the step-by-step technical workflow utilized on OYANG converting cells:
The slitted master roll of PP spunbond fabric is loaded onto a shaftless pneumatic chuck unwind station. An electronic photo-sensor edge position control (EPC) system detects lateral roll drift, dynamically pivoting the steering carriage within ±0.5 mm to ensure flawless downstream fold alignment.
For branded supermarket bags, the continuous web passes through high-speed printing units prior to gusseting. Converters utilize in-line 4-color central impression flexo printers or roll-to-roll screen printers to register logos using non-toxic water-based eco inks.
The moving web is guided over forming collars and precision steel plows to tuck side and bottom gussets. For 3D box bag production, continuous folding creates the rectangular volumetric depth without manual pre-creasing.
Ultrasonic transducers vibrating at 20 kHz convert electrical high frequency into localized mechanical frictional energy. As the sonotrode horn presses against patterned steel anvil rollers, the localized thermoplastic fibers soften instantly at the seam joints, creating airtight side seals and decorative embossed edge borders.
Secondary unwind reels supply narrow non-woven handle strips. Servo pullers measure the programmed loop length, dual cutters shear the handles, and pneumatic mechanical grippers position the loop ends directly beneath ultrasonic horns to fuse them to the bag hem with pull strengths exceeding 150 N.
A heavy-duty rotary or eccentric guillotine knife shears the continuously sealed web into discrete individual bags. Multi-axis servo timing guarantees length cut accuracy within ±1.0 mm at maximum line speeds.
Finished bags are transferred via high-speed vacuum discharge belts to robotic stacking arms. Once the pre-set batch count (typically 25, 50, or 100 bags) is reached, automatic bundling units strap the stack, delivering ready-to-box cartons without manual handling labor.
When calculating how to manufacture a bag at velocities exceeding 90 to 100 bags per minute, chassis structural vibration is the primary cause of seam failure. A chassis deflection of just ±0.03 mm alters the acoustic horn-to-anvil clearance, causing cold spots (leaks) or horn over-compression (pinholing).
Japanese MAZAK automated CNC lines at OYANG processing core structural wallboards to ≤ 0.015 mm flatness.
At OYANG’s 130,000㎡ smart manufacturing base, all load-bearing wallboards and eccentric drive shafts are machined on Japanese MAZAK and OKUMA 5-axis CNC centers. Holding planar tolerances within ≤ 0.015 mm ensures ultrasonic horns operate with dynamic harmonic balance, reducing fabric scrap to below 1.5% and extending ultrasonic horn service life beyond 18,000 production hours.
The OYANG TECH 23 is the industry benchmark for commercial takeaway and retail tote bag manufacturing. Operating at 90–100 bags/min, it features a patented 90-second automated mold changeover system.
For commercial facilities seeking maximum versatility, the OYANG XB700/800 converts flat D-cut bags, shoe bags, soft-handle bags, and drawstring gift pouches on a single unified chassis at 40–100 bags/min.
To review complete production capacity diagrams and engineering layouts, download the official OYANG Nonwoven Bag Making Machine Solution Brochure (PDF).
Non-woven bags are made by loading rolls of PP spunbond non-woven fabric onto an automated converting line where the fabric is guided, folded with side and bottom gussets, thermally bonded using 20 kHz ultrasonic horns, attached with loop handles, and rotary cross-cut into finished bags at up to 100 bags per minute without thread stitching.
Non-woven bags are made by bonding thermoplastic polypropylene filaments into rolls using heat and pressure (spunbond process), then unwinding and passing those rolls through automated converting machinery that performs edge position control, ultrasonic pattern sealing, handle welding, and computerized knife cutting.
To manufacture non-woven bags commercially, set up a production line comprising raw material fabric roll staging, a high-speed multi-axis servo bag making machine (such as the OYANG TECH 23), in-line ultrasonic welding generators, a loop handle applicator, and automated stacking or bundling units.
Manufacturing a bag requires feeding continuous substrate web (non-woven fabric, paper, or flexible film) through tension rollers, creating depth via mechanical gusset formers, sealing seams through ultrasonic or thermal heat bars, securing carrying handles, and shearing the continuous web to specified dimensions using synchronous cutting knives.
The predominant material used in non-woven bags is 100% virgin polypropylene (PP) spunbond non-woven fabric. Additional substrates include eco-friendly RPET (recycled polyethylene terephthalate), biodegradable PLA (polylactic acid), and BOPP films for photo-quality laminated surfaces.
The three main types of nonwoven fabric are Spunbond non-woven (high-strength continuous filament fabric used for shopping bags and protective wear), Meltblown non-woven (microfiber porous barrier fabric used for mask filtration), and Spunlace non-woven (hydroentangled soft fabric used for medical wipes and hygiene products).
From raw PP spunbond fabric extrusion lines to automated 3D box bag converting cells, OYANG Group delivers end-to-end machinery solutions backed by precision Japanese CNC manufacturing. Consult with our senior process engineers today.
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